Potterton Apollo installation and servicing manual

60 Pages·2012·9.77 MB·English

You can rely on
Installation & Service Instructions Apollo
Condensing
Combination Boiler
These instructions include the Benchmark Commissioning
Checklist and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2012
Natural Gas Building Regulations and the Benchmark Commissioning
Checklist
Potterton Apollo 25
G.C.No47-393-38
Building Regulations (England & Wales) require notification of
Potterton Apollo 30 the installation of a heating appliance to the relevant Local
G.C.No47-393-37 Authority Building Control Department. From 1 April 2005 this
can be achieved via a Competent Persons Self Certification
Scheme as an option to notifying the Local Authority directly.
Similar arrangements will follow for Scotland and will apply in
Northern Ireland from 1 January 2006.
The Health & Safety Executive operates the ‘Gas Safe Register’,
a self-certification scheme for gas heating appliances.
These arrangements represent a change from the situation
whereby compliance with Building Regulations was accepted as
being demonstrated by completion of the Benchmark Logbook
(which was then left on site with the customer).
With the introduction of Self Certification Schemes, the
Benchmark Logbook is being withdrawn. However, a similar
document in the form of a commissioning checklist and service
interval record is incorporated at the back of these instructions.
The Benchmark Scheme This company is a member of the Benchmark initiative and fully
supports the aims of the programme. Its aim is to improve the
Benchmark places responsibilities on both manufacturers and installers. The
purpose is to ensure that customers are provided with the correct equipment for standards of installation and commissioning of central heating
their needs, that it is installed, commissioned and serviced in accordance with the systems in the UK and to encourage the regular servicing of all
manufacturer’s instructions by competent persons and that it meets the
requirements of the appropriate Building Regulations. The Benchmark Checklist central heating systems to ensure safety and efficiency.
can be used to demonstrate compliance with Building Regulations and should be
provided to the customer for future reference.
Building Regulations require that installations should comply
Installers are required to carry out installation, commissioning and servicing work with manufacturer's instructions. It is therefore important that
in accordance with the Benchmark Code of Practice which is available from the
the commissioning checklist is completed by the installer. The
Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.ukfor more information. relevant section of Building Regulations only relates to
dwellings. Therefore the checklist only applies if the appliance is
being installed in a dwelling or some related structure.
© Baxi Heating UK Ltd 2012 All rights reserved. No part of this publication may
be reproduced or transmitted in any form or by any means, or stored in any The flowchart opposite gives guidance for installers on the
retrieval system of any nature (including in any database), in each case whether process necessary to ensure compliance with Building
electronic, mechanical, recording or otherwise, without the prior written
Regulations.
permission of the copyright owner, except for permitted fair dealing under
Copyrights, Designs and Patents Act 1988.
Applications for the copyright owner’s permission to reproduce or make other
use of any part of this publication should be made, giving details of the proposed
use, to the following address:
The Company Secretary, BaxiHeating UK Ltd,
Brooks House, Coventry Road, Warwick. CV34 4LL
Full acknowledgement of author and source must be given.
WARNING:Any person who does any unauthorised act in relation to a
copyright work may be liable to criminal prosecution and civil claims for damages.
0086
ISO 9001
FM 00866
2 © Baxi Heating UK Ltd 2012
Installer Notification Guidelines
Choose Building
Regulations Notification
Route
Competent Person's Building Control
Self Certification Scheme
Install and Commission this Contact your relevant Local
appliance to manufacturer's Authority Building Control
instructions (LABC) who will arrange
an inspection or contact
a government approved
inspector
Complete the
Benchmark Checklist
If you notify via the ‘Gas Safe
Register’, the register will issue
the Building Regulations
Install and Commission this
certificate on members’ behalf
appliance to manufacturer's
instructions
Scheme Members only
Call ‘Gas Safe Register’ on: Complete the
0800 408 5577 Benchmark Checklist
or log onto:
www.gassaferegister.co.uk
within 10 days
You must ensure that the
certificate number issued by
the ‘Gas Safe Register’ is written
onto the Benchmark Checklist
‘Gas Safe Register’ will issue a
LABC will record the data
Building Regulations Compliance
and will issue a
Certificate to the property owner
certificate of compliance
and inform the relevant LABC
© Baxi Heating UK Ltd 2012 3
Legislation
IMPORTANT - Installation, Commissioning, Service & Repair
This company declare that no substances harmful to health
are contained in the appliance or used during appliance
This appliance must be installed in accordance with the manufacturer’s instructions and
manufacture.
the regulations in force. Read the instructions fully before installing or using the
appliance.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force, and
In GB, this must be carried out by a competent person as stated in the Gas Safety only used in a suitably ventilated location.
(Installation & Use) Regulations.
In GB, the installation must be carried out by a Gas Safe
Registered Installer. It must be carried out in accordance with
Definition of competence:A person who works for a Gas Safe registered company
the relevant requirements of the:
and holding current certificates in the relevant ACS modules, is deemed competent. • Gas Safety (Installation & Use) Regulations.
• The appropriate Building Regulations either The Building
In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
Gas Installations”.
• The Water Fittings Regulations or Water Byelaws in
Scotland.
The addition of anything that may interfere with the normal operation of the appliance • The Current I.E.E. Wiring Regulations.
without express written permission from the manufacturer or his agent could invalidate
the appliance warranty. In GB this could also infringe the Gas Safety (Installation and Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
Use) Regulations.
In IE, the installation must be carried out by a competent
Warning -Check the information on the data plate is compatible with local supply Person and installed in accordance with the current edition of
conditions. I.S. 813 ‘Domestic Gas Installations’, the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
All Gas Safe registered engineers carry an IDcard with their licence number and a All systems must be thoroughly flushed and treated with
inhibitor (see section 6.2).
photograph. You can check your engineer is registered by telephoning
0800 408 5500 or online at www.gassaferegister.co.uk
The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)
Regulations 1993 No3083” and is deemed to meet the requirements of Directive Codes of Practice - refer to the most recent version
92/42/EEC on the energy efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels:- In GB the following Codes of Practice apply:
Standard Scope
BS 6891 Gas Installation.
Type test for purpose of Regulation 5 certified by: BS 5546 Installation of hot water supplies for domestic
purposes.
Notified Body 0087. BS EN 12828 Heating systems in buildings.
BS EN 12831 Heating systems in building - calculation of load.
BS EN 14336 Installation & commissioning of water based
Product/Production certified by: heating systems.
Notified Body 0086. BS 6798 Installation of gas fired hot water boilers.
BS 5440 Part 1 Flues.
BS 5440 Part 2 Ventilation.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
For GB/IE only. BS 7593 Treatment of water in domestic hot water
central heating systems.
In IE the following Codes of Practice apply:
Standard Scope
I.S. 813 Domestic Gas Installations.
The following standards give valuable additional information;
BS 5546 Installation of hot water supplies for domestic
purposes.
BS EN 12828 Heating systems in buildings.
BS EN 12831 Heating systems in building - calculation of load.
BS EN 14336 Installation & commissioning of water based
heating systems.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.
4 © Baxi Heating UK Ltd 2012
Safe Manual Handling
General
The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.
Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands.
Health & Safety is the responsibility of EVERYONE.
There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.
Do not handle or lift unless you feel physically able.
Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.
Preparation
Co-ordinate movements - know where, and when, you are both going.
Minimise the number of times needed to move the boiler - plan ahead.
Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care
on ladders/into lofts.

Technique
When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and
sideways and keep the load as close to your body as possible.
Where possible transport the boiler using a sack truck or other suitable trolley.
Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the
‘Installation’ section of these instructions for recommended lift points.
Remember
The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.
If at any time when installing the boiler you feel that you may have injured yourself STOP !!
DO NOT ‘work through’ the pain - you may cause further injury.
IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!
© Baxi Heating UK Ltd 2012 5
CONTENTS
Section Page
1.0 Introduction 7
2.0 General Layout 8
3.0 Appliance Operation 9
4.0 Technical Data 10
5.0 Dimensions and Fixings 11
6.0 System Details 12
7.0 Site Requirements 15
8.0 Flue Options 19
9.0 Plume Displacement 23
10.0 Installation 27
11.0 Commissioning 32
12.0 Completion 34
13.0 Servicing 35
14.0 Changing Components 37
15.0 Setting the Gas Valve 46
16.0 Electrical 47
17.0 Short Parts List 48
18.0 Fault Finding 49
Benchmark Checklist 58
6 © Baxi Heating UK Ltd 2012
1.0 Introduction
1.1 Description
1. The Potterton Apollo is a fully automatic gas fired wall
mounted condensing combination boiler. It is room sealed and
fan assisted, and will serve central heating and mains fed
Case Front Panel domestic hot water.
2. The boiler is set to give a maximum output of :-
25 models - 25.94 kW DHW
26.95 kW CH (Condensing)
30 models - 28.63 kW DHW
30.2 kW CH (Condensing)
3. It is designed for use on Natural Gas (G20).
4. The boiler is suitable for use only on fully pumped sealed
heating systems. Priority is given to domestic hot water.
5. The boiler data badge gives details of the model, serial
number and Gas Council number. It is visible when the case
front panel is removed and the control box hinged down
(Fig. 1).
6. The boiler model name and serial number are also shown
on the information label on the back of the facia door. This is
for user reference.
Control Box
7. The boiler is intended to be installed in residential /
commercial / light industrial E.M.C. environments on a
governed meter supply only.
Facia Door
8. The boiler must be installed with one of the purpose
designed flues such as the standard horizontal flue kit, part no.
Fig. 1 5118489 .
Information Label 9. All systems must be thoroughly flushed and treated with
Data Badge
inhibitor (see section 6.2).
1.2 Contents of Pack
1. Boiler Unit
2. Wall Mounting Plate
3. Set of Pipes & Taps (inc. nuts)
4. Template & ‘Quick Fit’ Guide
5. Literature Pack
© Baxi Heating UK Ltd 2012 7
13
15
2.0 General Layout
23
2.1 Layout
1. Expansion Vessel
1 2. Diverter Valve Motor
22
3. DHW Plate Heat Exchanger
14 4. Circulation Pump
5. Automatic Air Vent
21 6. Pressure Relief Valve
7. Selector Switch
8. Central Heating System Pressure Gauge
9. PCB
16 10. Control Box
12. Condensate Trap
13. Heat Exchanger Air Vent
14. Electrode Assembly
15. Primary Heat Exchanger
16. Fan Assembly
17. On/Off/Reset Selector Switch
7 18. Central Heating Temperature Control
19. Hot Water Temperature Control
20. Water Pressure Sensor
21. Gas/Air Inlet
22. Burner Mounting Panel
23. Igniter
10 24. Burner On Light
9 25. Central Heating Mode Light
8
26. Domestic Hot Water Mode Light
28
29
27. Display
28. Position of Optional Integral Timer
29. Safety Thermostat
30. Gas Valve
12
20
3
6
5
30
Pump and pipework
removed for clarity
2
4
25 26
2
Reset
1 3
0 4
bar
17 27 24 18 19 8 28
8 © Baxi Heating UK Ltd 2012
3.0 Appliance Operation
1
Boiler Schematic 3.1 Central Heating Mode (Fig. 2)
27
1. With a demand for heating, the pump circulates water
through the primary circuit.
2 2. Once main burner ignites the fan speed controls the gas
20
rate to maintain the heating temperature measured by the
3 4
7 temperature sensor.
26 5 6 3. When the flow temperature exceeds the setting
temperature, a 3 minute delay occurs before the burner
relights automatically (anti-cycling). The pump continues to
8 run during this period.
25
4. When the demand is satisfied the burner is extinguished
24
and the pump continues to run for a period of 3 minutes
(Pump Overrun).
21
18 3.2 Domestic Hot Water Mode (Fig. 2)
23 9 2 2
11 28 17 1. Priority is given to the domestic hot water supply. A
demand at a tap or shower will override any central heating
16 10 1 5 14 13 12 requirement.
Fig. 2 2. The flow of water will operate the Hall Effect Sensor
which requests the 3 way valve to change position. This will
Key allow the pump to circulate the primary water through the
1 Primary Heat Exchanger DHW plate heat exchanger.
15 Domestic Hot Water Outlet
2 Burner
16 Heating Flow
3 Ignition Electrodes 3. The burner will light automatically and the temperature of
17 Pressure Gauge
4 Flame Sensing Electrode
18 Water Pressure Sensor the domestic hot water is controlled by the temperature
5 Gas Valve
6 Pump 20 Fan sensor.
21 Diverter Valve Assembly
7 Automatic Air Vent
22 Diverter Valve Motor
8 Plate Heat Exchanger 4. When the domestic hot water demand ceases the burner
23 Domestic Hot Water Flow Temperature Sensor
9 DHW Flow Sensor (‘Hall Effect’ Sensor)
24 Safety Thermostat will extinguish and the diverter valve will remain in the
10 Pressure Relief Valve
11 Boiler Drain Point 25 Central Heating Temperature Sensor domestic hot water mode, unless there is a demand for
26 Expansion Vessel
12 Heating Return central heating.
27 Heat Exchanger Air Vent
13 Cold Water Inlet On/Off Valve and Filter
28 By-pass Valve
14 Gas Inlet
IMPORTANT:When the selector switch is in the ‘0’
(Off) position the electrical supply to the boiler is isolated.
The boiler will not operate and the integral timer will
require resetting once the selector switch is set to either
Position ( ) or Position ( ).
3.3 Frost Protection Mode
1. The frost protection mode is integral to the appliance and
functions only with the selector switch (see Section 2.1) in
the domestic hot water and central heating position. If the
system temperature falls below 5° C then the boiler will fire
on its minimum setting until a flow temperature of 30° C is
reached. Further protection can be incorporated by using a
system frost thermostat.
3.4 Pump Protection
1. With the selector switch (see Section 2.1) in either the
central heating or central heating and domestic hot water
position, the pump will automatically operate for 1 minute in
every 24 hours to prevent sticking.
© Baxi Heating UK Ltd 2012 9
4.0 Technical Data
4.1 Potterton Apollo 25 & 30
Appliance Type C13 C33 C53 Inlet Pressure (Natural Gas - G20) NOxClass 5
mbar 20
Appliance Category CAT I 2H Central Heating Primary Circuit
Injector (Natural Gas - G20) Pressures
Heat InputCH (Net) Max Min
6.0mm bar
25 model kW 26.06 7.82 Safety Discharge 3
30 model kW 29.32 8.8 Electrical Supply 230V~ 50Hz Max Operating 2.5
(Appliance must be connected to an
Min Operating 0.5
Heat InputCH (Gross) Max Min earthed supply) Recommended Operating Range 1-2
25 model kW 28.92 8.68
Power Consumption DHW Circuit bar
30 model kW 32.54 9.77 150W Pressures
Max Operating 8
Electrical Protection
Heat Output CH (Non-Condensing) Min Operating 0.15
IPX0D (with timer)
Max Min
IPX4D (without timer) Flow Rates (25) (30)
25 model kW 25.94 7.61 l/min l/min
External Fuse Rating 3A
30 model kW 28.63 8.56 DHW Flow Rate
Internal Fuse Rating F2L @ 30o CRise 11.9 14.3
Heat Output CH (Condensing) Condensate Drain DHW Flow Rate
Max Min To accept 21.5mm (3/4in) plastic waste pipe @ 35o CRise 10.2 12.3
25 model kW 26.95 8.37 Flue Terminal Diameter 100mm Min Working
30 model kW 30.2 9.42 Dimensions Projection 125mm DHW Flow Rate 2 2
Heat Input DHW (Net) Max Connections copper tails IMPORTANT:Where Low Flow Taps or Fittings are
intended to be used in the DHW system connected it is
Gas Supply - 22mm
25 model kW 26.06 strongly recommended that the DHW flow rate DOES
Central Heating Flow - 22mm
NOT fall below 2.5l/min. This will ensure reliable
30 model kW 30.0 Central Heating Return - 22mm operation of the DHW function.
Cold Water Mains Inlet - 15mm
Heat Input DHW (Gross) Max
DHW Flow - 15mm Pump
25 model kW 28.92 Pressure Relief Discharge - 15mm Available Head See graph below
30 model kW 33.3 Outercase Dimensions Expansion Vessel - (For Central Heating
Casing Height - 780mm only. Integral with appliance)
Heat Output DHW Max Overall Height Inc Flue Elbow - 965mm bar
25 model kW 24.88 Casing Width - 450mm Min Pre-charge Pressure 0.5
30 model kW 30.0 Casing Depth - 345mm
(25) ( 30)
Clearances
Max Gas Rate (Natural Gas - G20) Above Casing 200 mm Min Max Capacity of litre litre
(After 10 mins) CH System 125 155
300mm Min (80/125)
25 model m3/h 2.76 Below Casing 200 mm Min
Primary Water Content
30 model m3/h 3.17 Front 450 mm Min(For Servicing) of Boiler (unpressurised) 3.1 3.1
Front 5 mm Min (In Operation)
L.H. Side 5 mm Min Temperatures
R.H. Side 5 mm Min (In Operation) C.H. Flow Temp (adjustable)
25°C to 80°C max (± 5°C)
Weights
Packaged Boiler Carton 54.7 kg D.H.W. Flow Temp (adjustable)
Installation Lift Weight 47.5 kg 35°C to 60°C max (± 5°C)
dependent upon flow rate
Pump - Available Head
NOTE:All data in this section are nominal values
and subject to normal production tolerances. 5.5
5
4.5
SEDBUK(2005) Declaration
4
The efficiency is 91.0% (25) 3.5
90.1% (30)
3
This value is used in the UK Government’s Standard
2.5
Assessment Procedure (SAP 2005) for energy rating wg)
of dwellings. The test data from which it has been Metre ( 2
calculated has been certified by 0086. 1.5
1
0.5
0
0 200 400 600 800 1000 1200 1400
10 © Baxi Heating UK Ltd 2012 Flow Rate (l/h)